The emission of toxic gases and aerosols is a major risk associated with the process of electric discharge machining (EDM), one of the most commonly used non-conventional manufacturing processes. These emissions can have adverse effects on the health of operators and have a direct impact on the environment. The emission of this process is directly related to the temperature at the process location. The objective of this work was to develop a model that quantifies the aerosol generated by the die sinking EDM process while machining the steel workpiece with copper electrode. The model developed in this work used the energy balance and the heat transfer equations.